Mar 29, 2015
Who are we?
Who are weWho are we??
• Polish Foundry Group (Polska Grupa Polish Foundry Group (Polska Grupa
Odlewnicza) is an association of two Odlewnicza) is an association of two
foundries: Pioma-Odlewnia Foundry foundries: Pioma-Odlewnia Foundry
and Iron Foundry Śrem.and Iron Foundry Śrem.
• Since October 2011 Polish Foundry Since October 2011 Polish Foundry
Group Group becomes a public company becomes a public company
listed on the Stock Exchange in listed on the Stock Exchange in
Warsaw.Warsaw.
PGO production facilities locationsPGO production facilities locations
Group structureGroup structure
Shareholders structureShareholders structure ((Oct. Oct. 2011)2011)
• PGO SA share capital amounts to 96.3 million zł and is divided into 96,000,000 shares with a nominal value of 1 zł each
General InformationsGeneral Informations
HistoryHistory
19601960 20002000 20062006 20082008 20102010
FFoundation of oundation of the foundry as the foundry as
a part of a part of Mining Mining
Machines Machines Factory Factory PIOMAPIOMA
Pioma-Odlewnia Pioma-Odlewnia Sp. z o.o. Sp. z o.o.
becomes an becomes an independent independent
business entity business entity as a limited as a limited companycompany
JoJoining the ining the FAMUR Capital FAMUR Capital
GroupGroup
AAcquisition of cquisition of ŚREM Iron ŚREM Iron
Foundry and Foundry and foundation of foundation of
Polish Foundry Polish Foundry GroupGroup
50 years 50 years of traditionof tradition
and experience and experience in castingin casting
Pioma-Odlewnia foundry is specialized in high class steel and iron Pioma-Odlewnia foundry is specialized in high class steel and iron
castings for: castings for:
• mining industry, mining industry,
• machinery and equipment, machinery and equipment,
• building machinery, building machinery,
• chemical industry, chemical industry,
• siderurgy and energetics, siderurgy and energetics,
• shipbuilding industry, shipbuilding industry,
• and others.and others.
Pioma-Odlewnia activityPioma-Odlewnia activity
Maximum production capacity – 10 200 tons/yearMaximum production capacity – 10 200 tons/year
Present employment - 320 employees Present employment - 320 employees
Pioma offer contains castings made of:Pioma offer contains castings made of:
• constructional carbon cast steelconstructional carbon cast steel
• alloy cast steel alloy cast steel
• cast ironcast iron
Pioma offers steel and iron castings from 5 to 5000 kg.Pioma offers steel and iron castings from 5 to 5000 kg.
General informationGeneral information
Foundry Presentation - P 14
Foundry Presentation - P 15
Investment plan for FY2012 and FY2013Investment plan for FY2012 and FY2013
No Investments optimizing the production processDATE OF
COMPLETION
1 Modernization of hydraulic and control system of EAFs 2012-2013
2 Leadles heating system II qu. 2013
3 Modernization of sand reclamation and distribution stationIV qu 2012 - I qu.
2013 ongoing
4 New polymer quenching tanks with cooling system done
5 New turning lathe done
6 Pneumatic hammer for risers removal (manganese steel) done
7 Heat treatment furnace modernization No 1 II qu. 2013
8 New Spectrometer III qu. 2013
No EHS investmentsDATE OF
COMPLETION
1 EAFs dedusting system 2012-2013
2 Cutting stations dedusting system IIqu. 2013
3 Grinding stations dedusting system IVqu. 2013
Estimaed cost of the realization is ~2.5 mln €Estimaed cost of the realization is ~2.5 mln €
Production Process FlowProduction Process Flow
Foundry technologydesign
Conductance of process simulation Pattern-making Moulding
Melting, refining & pouring Shakeout & cleaning
Welding Machining Painting & Shipment
Lay-out & NDTHeat Treatment
The technical data are supported by MAGMASOFTThe technical data are supported by MAGMASOFT®®
program for simulation of metal solidification, a program for simulation of metal solidification, a
comprehensive solution which enables to: design and comprehensive solution which enables to: design and
analyze technical casting correctness, design gating and analyze technical casting correctness, design gating and
feeder systems, make a reliable pattern set and other feeder systems, make a reliable pattern set and other
tools, optimalize of a casting process, control of quality.tools, optimalize of a casting process, control of quality.
Engineering departmentEngineering department
Pattern shopPattern shop
The patten-shop contains the stock of machines and The patten-shop contains the stock of machines and
tools used for the production of:tools used for the production of:• wooden patterns with the overall dimension of 3000 x wooden patterns with the overall dimension of 3000 x
2500 x 1500 mm 2500 x 1500 mm • metal metal patternspatterns with the overall dimensions of 1000 x with the overall dimensions of 1000 x
800 x 300 mm.800 x 300 mm.
The melting shop is equipped with:The melting shop is equipped with:
• two arc furnaces with the capacity of 3T each one two arc furnaces with the capacity of 3T each one
with the capacity of 6T and with the capacity of 6T and
• an induction ABB furnace with the capacity of an induction ABB furnace with the capacity of
2 x 2,5T.2 x 2,5T.
Melting shopMelting shop
Moulding shopMoulding shop
On machine-moulding line we produce castings On machine-moulding line we produce castings
up to 150 kg weightup to 150 kg weight in moulding flasks of the in moulding flasks of the
dimensions 1000 x 700 x (340+270) mm. dimensions 1000 x 700 x (340+270) mm.
On hand-moulding line we produce castings of On hand-moulding line we produce castings of
weight up to weight up to 55000 kg and maximum dimensions 3000 000 kg and maximum dimensions 3000
x 3000 x 2000 mm.x 3000 x 2000 mm.
The fettling shop is equipped with two conveyor The fettling shop is equipped with two conveyor
wheelabrator fettling plant: Pangborn and Tilghman and wheelabrator fettling plant: Pangborn and Tilghman and
with two shot blast chambers and turntables OWPK-4with two shot blast chambers and turntables OWPK-4..
Fettling shopFettling shop
Heat treatmentHeat treatment
Heat treatment department is equipped with:Heat treatment department is equipped with:
• 4 gas-fired furnaces with gas stoves of 15m4 gas-fired furnaces with gas stoves of 15m22;;
• tunnel-furnace for quenching and tempering made by tunnel-furnace for quenching and tempering made by
Siemens with the pallet size of 1250 x 750mm.Siemens with the pallet size of 1250 x 750mm.
Quality and EnviromentQuality and Enviroment
Quality Management System
ISO 9001:2008
IPPC Certificate (Integrated Pollution Prevention and Control)
Other:Other:•Accreditation Certificate of Testing Laboratory Accreditation Certificate of Testing Laboratory •LR Certificate for production of Steel and Cast Iron LR Certificate for production of Steel and Cast Iron CastingsCastings•GL Certificate for production of Steel and Cast Iron GL Certificate for production of Steel and Cast Iron CastingsCastings•DNV Certificate for production of Steel Castings DNV Certificate for production of Steel Castings
PiomaPioma testing laboratory is one of the most modern and high equipped industrial laboratory in the country. It provides services for testing laboratory is one of the most modern and high equipped industrial laboratory in the country. It provides services for
the foundry but also for outside clients in accordance withthe foundry but also for outside clients in accordance with PN-EN ISO/IEC 17025:2005 standard.PN-EN ISO/IEC 17025:2005 standard.
Certification:Certification:
• Certificate of approval for Testing Laboratory Certificate of approval for Testing Laboratory
No. L-II-104/20 No. L-II-104/20
credited by Office of Technical Inspectioncredited by Office of Technical Inspection
• Accreditation Certificate of Testing Laboratory Accreditation Certificate of Testing Laboratory
No. AB 205 No. AB 205
credited by Polish Centre For Accreditationcredited by Polish Centre For Accreditation
Testing laboratoryTesting laboratory
Scope of services:Scope of services:
• chemical analysis chemical analysis rangerange: steels and cast steels, low-alloyed and highly alloyed, grey cast irons, alloyed and spheroid cast irons: steels and cast steels, low-alloyed and highly alloyed, grey cast irons, alloyed and spheroid cast irons
equipmentequipment:: the emission meter of quantum ARL-3460, carbon and sulphur analyzer LECO CS – 125, oxygen the emission meter of quantum ARL-3460, carbon and sulphur analyzer LECO CS – 125, oxygen
and nitrogen analyzer LECO TC 500and nitrogen analyzer LECO TC 500
• resistance tests resistance tests rangerange: static test of bumping to determine R02, Re, Rm, A5, Z, E; Charpy impact strength test of temperature : static test of bumping to determine R02, Re, Rm, A5, Z, E; Charpy impact strength test of temperature
starting from - 75°C, Brinell, Vickers, Rockwell hardness test, static test of bendingstarting from - 75°C, Brinell, Vickers, Rockwell hardness test, static test of bending
equipmentequipment: impact hammer RKP 450, universal testing machine ZWICK: impact hammer RKP 450, universal testing machine ZWICK
Testing laboratoryTesting laboratory
• metallographic testsmetallographic testsrangerange: macro and microscopy : macro and microscopy
metallographymetallography
equipmentequipment: metallographic microscope : metallographic microscope
NEOPHOT 32R with the magnifying NEOPHOT 32R with the magnifying
power of 10 - 2000x, metallographic power of 10 - 2000x, metallographic
microscope EPITYP 2 with the microscope EPITYP 2 with the
magnifying power of 10 – 2000x, program magnifying power of 10 – 2000x, program
for picture analysis – LUCIAfor picture analysis – LUCIA
Testing laboratoryTesting laboratory
Non Destructive TestsNon Destructive Tests
MT Magnetic Particle Inspection
UTUltrasonic Examination
PTDye penetrant Inspection
Acceptance Standards:•EN 1369•EN ISO 23278Examination Instructions;•EN ISO 9934 part 1-3•EN ISO 17638•ASTM E709•acc. to customer requirementsExamination Method:•magnetic yokeExamination Medium:Wet system particle:•Black Powder•Fluorescent PowderInstruments:•Portable Flawcheck Defectoscope AC230•Portable Flawcheck Defectoscope UM-9/230•Portable Flawcheck Defectoscope B300S
Acceptance Standards:•ISO 5817•EN 12680-1, -2, -3•EN ISO 116666Examination Instructions;•EN 583-1•EN ISO 17640•ASTM A 609•EN 14127•acc. to customer requirementsExamination Method:•DAC diagram•DGS diagram•ScalesInstruments:•Ultrasonic Flaw Detectors USM 25S•Ultrasonic Flaw Detectors USM 35S•Ultrasonic Flaw Detectors EPOCH 600•Ultrasonic Thickness Gauge MC-300Ultrasonic Transducer:•Single crystal normal probes•Single crystal angle probes•Double crystal angle probes•Double crystal normal probes
Acceptance Standards:•EN 23277•EN 1371-1Examination Instructions;•EN 571-1•ASTM E 165•acc. to customer requirementsExamination Method:•AreosolType of dye:•Fluorescent•NonfluorescentExamination Means:•MR CHEMIE
Products samplesProducts samples – mining industry – mining industry
Cover Cover GJL250GJL25036 kg36 kg
Teeth Teeth L120G13, L35GSML120G13, L35GSM
6 kg6 kg
Chain wheel half Chain wheel half L30GSL30GS33 kg33 kg
GuideGuide L450L45017 kg17 kg
SocketSocket A A6618 kg18 kg
Housing GJL200Housing GJL20020 kg20 kg
Fastening Fastening GGG50/ GJS500-7 GGG50/ GJS500-7
20kg20kg
Link Gs52Link Gs528 kg8 kg
Products samplesProducts samples – mining industry – mining industry
Arm body Arm body L25GNMF/L20HGSNM L25GNMF/L20HGSNM
3350kg3350kg
Piston element A6Piston element A670 kg70 kg
BoBoddy L30GSy L30GS45 kg45 kg
Chain wheel half Chain wheel half L35GSML35GSM400 kg400 kg
ProfileProfile A6A6420 kg420 kg
Chain wheel Chain wheel GS52 56 kgGS52 56 kg
Ladder Ladder L35GSML35GSM
60 kg60 kg
Products samplesProducts samples – machinery – machinery
Housing GJL200Housing GJL20090 kg90 kg
Wheel GGG60/ GJS600-3 Wheel GGG60/ GJS600-3 16 kg16 kg
Socket A6Socket A618 kg18 kg
Cover Nihard ICover Nihard I8 kg8 kg
Bearing housing Bearing housing GJL250 41 kgGJL250 41 kg
Products samplesProducts samples – machinery – machinery
Housing GJS500-7 Housing GJS500-7 450 kg450 kg
Body GG25/GJL250Body GG25/GJL250450 kg450 kg
Link GS34CrMo4 Link GS34CrMo4 150-380kg150-380kg Yoke L35GSM Yoke L35GSM
100 kg100 kg
Products samplesProducts samples – industrial fittings – industrial fittings
Body GG25 / Body GG25 / GJL250 8kgGJL250 8kg
Body GJL250Body GJL25028 kg28 kg
Body GJS 400-15Body GJS 400-1510-180 kg10-180 kg
Ring GJS500-7Ring GJS500-72 kg2 kg
Body GJL250 Body GJL250 15-20 kg15-20 kg
Casing GJS400-15, GJL250Casing GJS400-15, GJL2507-15 kg7-15 kg
Products samplesProducts samples – industrial fittings – industrial fittings
Wedge Wedge 420-12 420-12 1000 kg1000 kg
Pump casing A48CL40, Pump casing A48CL40, GR60-40-18 1500-3500 kgGR60-40-18 1500-3500 kg